Photovoltaic device including an intermediate layer

ABSTRACT

Methods and apparatus are provided for converting electromagnetic radiation, such as solar energy, into electric energy with increased efficiency when compared to conventional solar cells. In one embodiment of a photovoltaic (PV) device, the PV device generally includes an n-doped layer and a p + -doped layer adjacent to the n-doped layer to form a p-n layer such that electric energy is created when electromagnetic radiation is absorbed by the p-n layer. The n-doped layer and the p + -doped layer may compose an absorber layer having a thickness less than 500 nm. Such a thin absorber layer may allow for greater efficiency and flexibility in PV devices when compared to conventional solar cells.

CROSS-REFERENCE TO RELATED APPLICATIONS

Under 35 U.S.C. §120, this application is a divisional application andclaims the benefit of priority to U.S. patent application Ser. No.12/605,129, filed Oct. 23, 2009 and U.S. Provisional Patent ApplicationSer. No. 61/107,959, filed Oct. 23, 2008, all of which is incorporatedherein by reference.

BACKGROUND

1. Technical Field

Embodiments of the present invention generally relate to photovoltaic(PV) devices, such as solar cells, with increased efficiency and greaterflexibility and methods for fabricating the same.

2. Description of the Related Art

As fossil fuels are being depleted at ever-increasing rates, the needfor alternative energy sources is becoming more and more apparent.Energy derived from wind, from the sun, and from flowing water offerrenewable, environment-friendly alternatives to fossil fuels, such ascoal, oil, and natural gas. Being readily available almost anywhere onEarth, solar energy may someday be a viable alternative.

To harness energy from the sun, the junction of a solar cell absorbsphotons to produce electron-hole pairs, which are separated by theinternal electric field of the junction to generate a voltage, therebyconverting light energy to electric energy. The generated voltage can beincreased by connecting solar cells in series, and the current may beincreased by connecting solar cells in parallel. Solar cells may begrouped together on solar panels. An inverter may be coupled to severalsolar panels to convert DC power to AC power

Nevertheless, the currently high cost of producing solar cells relativeto the low efficiency levels of contemporary devices is preventing solarcells from becoming a mainstream energy source and limiting theapplications to which solar cells may be suited. Accordingly, there is aneed for more efficient photovoltaic devices suitable for a myriad ofapplications.

SUMMARY OF THE INVENTION

Embodiments of the present invention generally relate to methods andapparatus for converting electromagnetic radiation, such as solarenergy, into electric energy with increased efficiency when compared toconventional solar cells

One embodiment of the present invention provides a photovoltaic (PV)device. The PV device generally includes an n-doped layer and a p⁺-dopedlayer adjacent to the n-doped layer to form a p-n layer such thatelectric energy is created when electromagnetic radiation is absorbed bythe p-n layer.

Another embodiment of the present invention is a method of fabricating aPV device. The method generally includes forming an n-doped layer abovea substrate and forming a p⁺-doped layer above the n-doped layer tocreate a p-n layer between the n-doped layer and the p⁺-doped layer suchthat electric energy is created when electromagnetic radiation isabsorbed by the p-n layer.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above-recited features of the inventioncan be understood in detail, a more particular description of theinvention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 illustrates multiple epitaxial layers for a photovoltaic (PV)unit in cross-section with example thickness, composition, and doping ofthe semiconductor layers, in accordance with an embodiment of thepresent invention.

FIGS. 2A-D illustrate various layer stack profiles for the base andemitter layers of the PV unit, in accordance with embodiments of thepresent invention.

FIGS. 3A and 3B illustrate semiconductor layers for a PV unit withoffset p-n layers between the base and emitter layers, in accordancewith embodiments of the present invention.

FIG. 4 illustrates semiconductor layers for a PV unit with an emitterlayer having a doping profile fine-tuned such that the doping levelsincrease from the p-n layer to the top of the emitter layer, inaccordance with an embodiment of the present invention.

FIG. 5 illustrates semiconductor layers for a PV unit with multipleAlGaAs emitter layers having graded aluminum (Al) levels, in accordancewith an embodiment of the present invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide techniques and apparatusfor converting electromagnetic radiation, such as solar energy, intoelectric energy with increased efficiency when compared to conventionalsolar cells.

An Exemplary Thin Absorber Layer

FIG. 1 illustrates various epitaxial layers of a photovoltaic (PV) unit100 in cross-section during fabrication. The various layers may beformed using any suitable method for semiconductor growth, such asmolecular beam epitaxy (MBE) or metalorganic chemical vapor deposition(MOCVD), on a substrate (not shown).

To form the PV unit 100, one or more buffer layers may be formed on thesubstrate. The purpose of the buffer layer(s) is to provide anintermediary between the substrate and the semiconductor layers of thefinal PV unit that can accommodate their different crystallographicstructures as the various epitaxial layers are formed. Having athickness of about 200 nm, for example, a buffer layer 102 may comprisea group III-V compound semiconductor, such as gallium arsenide (GaAs),depending on the desired composition of the final PV unit. For someembodiments, for example, the substrate may comprise GaAs when creatinga GaAs buffer layer.

For some embodiments, a release layer 104 may be formed above the bufferlayer 102. The release layer 104 may comprise aluminum arsenide (AlAs),for example, and have a thickness in a range from about 5 to 10 nm. Thepurpose of the thin release layer 104 is described in greater detailbelow.

Above the release layer 104, a window layer 106 may be formed. Thewindow layer 106 may comprise aluminum gallium arsenide (AlGaAs), suchas Al_(0.3)Ga_(0.7)As. The window layer 106 may have a thickness in arange of about 5 to 30 nm (e.g., 20 nm as shown) and may be undoped. Thewindow layer 106 may be transparent to allow photons to pass through thewindow layer on the front side of the PV unit to other underlyinglayers.

A base layer 108 may be formed above the window layer 106. The baselayer 108 may comprise any suitable group III-V compound semiconductor,such as GaAs. The base layer 108 may be monocrystalline. The base layer108 may be n-doped, and for some embodiments, the doping concentrationof the n-doped base layer 108 may be in a range from about 1×10¹⁶ to1×10¹⁹ cm⁻³ (e.g., 2×10¹⁷ cm⁻³ as shown). The thickness of the baselayer 108 may be in a range from about 300 to 3500 nm.

As illustrated in FIG. 1, an emitter layer 110 may be formed above thebase layer 108. The emitter layer 110 may comprise any suitable groupIII-V compound semiconductor for forming a heterojunction with the baselayer 108. For example, if the base layer 108 comprises GaAs, theemitter layer 110 may comprise a different semiconductor material, suchas AlGaAs. If the emitter layer 110 and the window layer 106 bothcomprise AlGaAs, the Al_(x)Ga_(1−x)As composition of the emitter layer110 may be the same as or different than the Al_(y)Ga_(1−y)Ascomposition of the window layer 106. The emitter layer 110 may bemonocrystalline. The emitter layer 110 may be heavily p-doped (i.e.,p⁺-doped), and for some embodiments, the doping concentration of thep⁺-doped emitter layer may be in a range from about 1×10¹⁷ to 1×10²⁰cm⁻³ (e.g., 1×10¹⁹ cm⁻³ as shown). The thickness of the emitter layer110 may be about 300 nm, for example. The combination of the base layer108 and the emitter layer 110 may form an absorber layer for absorbingphotons. For some embodiments, the absorber layer may have a thicknessless than 800 nm, or even less than 500 nm.

The contact of an n-doped base layer to a p⁺-doped emitter layer createsa p-n layer 112. When light is absorbed near the p-n layer 112 toproduce electron-hole pairs, the built-in electric field may force theholes to the p⁺-doped side and the electrons to the n-doped side. Thisdisplacement of free charges results in a voltage difference between thetwo layers 108, 110 such that electron current may flow when a load isconnected across terminals coupled to these layers.

Rather than an n-doped base layer 108 and a p⁺-doped emitter layer 110as described above, conventional photovoltaic semiconductor devicestypically have a p-doped base layer and an n⁺-doped emitter layer. Thebase layer is typically p-doped in conventional devices due to thediffusion length of the carriers. Fabricating a thinner base layeraccording to embodiments of the invention allows for the change to ann-doped base layer. The higher mobility of electrons in an n-doped layercompared to the mobility of holes in a p-doped layer leads to the lowerdoping density in the n-doped base layer 108 of embodiments of theinvention.

Once the emitter layer 110 has been formed, cavities or recesses 114 maybe formed in the emitter layer deep enough to reach the underlying baselayer 108. Such recesses 114 may be formed by applying a mask to theemitter layer 110 using photolithography, for example, and removing thesemiconductor material in the emitter layer 110 not covered by the maskusing any suitable technique, such as wet or dry etching. In thismanner, the base layer 108 may be accessed via the back side of the PVunit 100.

For some embodiments, an interface layer 116 may be formed above theemitter layer 110. The interface layer 116 may comprise any suitablegroup III-V compound semiconductor, such as GaAs. The interface layer116 may be p⁺-doped, and for some embodiments, the doping concentrationof the p⁺-doped interface layer 116 may be 1×10¹⁹ cm⁻³. The thickness ofthe interface layer 116 may be about 300 nm, for example.

Once the remaining epitaxial layers have been formed above the releaselayer 104, the thin release layer 104 may be sacrificed via etching withaqueous HF, for example. In this manner, the functional layers of the PVunit 100 (e.g., the window layer 106, the base layer 108, and theemitter layer 110) may be separated from the buffer layer(s) 102 andsubstrate during the epitaxial lift-off (ELO) process.

A PV unit created in this manner has a significantly thin absorber layer(e.g., <500 nm) compared to conventional solar units, which may beseveral micrometers thick. The thickness of the absorber layer isproportional to dark current levels in the PV unit (i.e., the thinnerthe absorber layer, the lower the dark current). Dark current is thesmall electric current that flows through the PV unit or other similarphotosensitive device (e.g., a photodiode) even when no photons areentering the device. This background current may be present as theresult of thermionic emission or other effects. Because the open circuitvoltage (V_(oc)) increases as the dark current is decreased in aphotosensitive semiconductor device, a thinner absorber layer may mostlikely lead to a greater V_(oc) for a given light intensity and, thus,increased efficiency. As long as the absorber layer is able to traplight, the efficiency increases as the thickness of the absorber layeris decreased.

The thinness of the absorber layer may not only be limited by thecapabilities of thin film technology and ELO. For example, efficiencyincreases with the thinness of the absorber layer, but the absorberlayer should be thick enough to carry current. However, higher dopinglevels may allow current to flow, even in very thin absorber layers.Therefore, increased doping may be utilized to fabricate very thinabsorber layers with even greater efficiency. Conventional PV devicesmay suffer from volume recombination effects, and therefore, suchconventional devices do not employ high doping in the absorber layer.The sheet resistance of the absorber layer may also be taken intoconsideration when determining the appropriate thickness.

Not only does a thin absorber layer lead to increased efficiency, but PVunits with such a thin absorber layer may be more flexible thanconventional solar cells having a thickness of several micrometers.Therefore, PV units according to embodiments of the invention may beappropriate for a greater number of applications than conventional solarcells.

FIGS. 2A-D illustrate various layer stack profiles 200 _(a-d) for thebase and emitter layers 108, 110 of the PV unit, in accordance withembodiments of the present invention. The layer stack profile 200 _(a)in FIG. 2A illustrates the base and emitter layers 108, 110 asillustrated in FIG. 1. For some embodiments, an intermediate layer 202may be formed above the base layer 108, and the emitter layer 110 may beformed above the intermediate layer. The intermediate layer 202 mayprovide a more gradual transition between the base and emitter layers108, 110.

The intermediate layer 202 may be n-doped, heavily n-doped (i.e.,n⁺-doped), or p⁺-doped. For example, FIG. 2B illustrates an intermediatelayer 202 _(b) comprising n-AlGaAs. As another example, FIG. 2C depictsan intermediate layer 202 _(c) comprising n⁺-AlGaAs. As yet anotherexample, FIG. 2D portrays an intermediate layer 202 _(d) comprisingp⁺-GaAs.

In FIG. 1, the p-n layer 112 between the base layer 108 and the emitterlayer 110 is flat and is not exposed in the recesses 114. In otherwords, the p-n layer 112 of FIG. 1 may be considered as a plane havingonly two-dimensional geometry. For some embodiments, as shown in FIGS.3A and 3B, the semiconductor layers for a PV unit may be formed tocreate an offset p-n layer 312 between the base and emitter layers 108,110. In other words, an offset p-n layer 312 may be considered to havethree-dimensional geometry. An offset p-n layer 312 may be exposed inthe recesses 114.

As illustrated in FIG. 3A, an offset p-n layer 312 _(a) may be producedby removing semiconductor material all the way through the emitter layer110 and partially into the base layer 108 when forming the recesses 114as described above. Another method of forming an offset p-n layer 312_(b), as illustrated in FIG. 3B, may comprise applying a mask to thebase layer 108 before forming the emitter layer 110. Semiconductormaterial may be removed via any suitable technique, such as etching,from a portion of the base layer 108 where the emitter layer is intendedto remain (i.e., everywhere except the desired locations of the recesses114). Once the emitter layer 110 and the recesses 114 are formed in theemitter layer, the resulting offset p-n layer 312 _(b) has a greatersurface area than a flat p-n layer 112.

For some embodiments, doping levels may be fine-tuned within a layer ofthe PV unit during fabrication. For example, FIG. 4 illustrates a PVunit 400 with an emitter layer 110 having a doping profile fine-tunedsuch that the doping concentration increases from the p-n layer 112 tothe top of the emitter layer 110 in the z-direction.

For some embodiments, the emitter layer 110 may comprise multiplelayers, and the multiple layers may comprise different compositions. Forexample, FIG. 5 illustrates semiconductor layers for a PV unit 500 withmultiple p⁺-AlGaAs emitter layers having graded aluminum (Al) levels(i.e., percentages), in accordance with an embodiment of the presentinvention. In this example embodiment, a first emitter layer 510 ₁comprising p⁺-GaAs without any aluminum may be formed above the baselayer 108. A second emitter layer 510 ₂ comprising p⁺-Al_(0.1)Ga_(0.9)Asmay be formed above the first emitter layer 510 ₁. Then, a third emitterlayer 510 ₃ comprising p⁺-Al_(0.2)Ga_(0.8)As and a fourth emitter layer510 ₄ comprising p⁺-Al_(0.3)Ga_(0.7)As may be formed above the secondemitter layer 510 ₂, in turn. Having such graded Al levels may avoidjunction barriers.

While the foregoing is directed to embodiments of the invention, otherand further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

The invention claimed is:
 1. A photovoltaic device, comprising: a n-doped GaAs layer; a p⁺-doped AlGaAs layer wherein recesses are formed in the p⁺-doped AlGaAs layer; a n-doped AlGaAs intermediate layer interposed between the n-doped GaAs layer and the p⁺-doped AlGaAs layer, wherein the n-doped intermediate AlGaAs layer and the p⁺-doped AlGaAs layer form a p-n junction such that electric energy is created when photons are absorbed by the p-n junction, and wherein the n-doped AlGaAs intermediate layer provides a transition between the n-doped GaAs layer and the p⁺-doped AlGaAs layer; and an interface layer comprising a Group III-V compound semiconductor above and indirect contact with the p⁺-doped AlGaAs layer, wherein a length in the horizontal direction of the p⁺-doped AlGaAs layer is longer than a length in the horizontal direction of the interface layer.
 2. The photovoltaic device of claim 1, wherein the p⁺-doped AlGaAs layer has a doping profile fine-tuned such that doping levels change from one side of the p⁺-doped AlGaAs layer to the other.
 3. A photovoltaic device, comprising: a n-doped GaAs layer; a p⁺-doped AlGaAs layer, wherein recesses are formed in the p⁺-doped AlGaAs layer; a n-doped AlGaAs intermediate layer comprising a plurality of layers wherein each of the plurality of layers comprises a different percentage of aluminum, the n-doped AlGaAs layer is interposed between the n-doped GaAs layer and the p⁺-doped AlGaAs layer, wherein the n-doped intermediate AlGaAs layer and the p⁺-doped AlGaAs layer form a p-n junction such that electric energy is created when photons are absorbed by the p-n junction, and wherein the n-doped AlGaAs intermediate layer provides a transition between the n-doped GaAs layer and the p⁺-doped AlGaAs layer; and an interface layer comprising a Group III-V compound semiconductor above and indirect contact with the p⁺-doped AlGaAs layer, wherein a length in the horizontal direction of the p⁺-doped AlGaAs layer is longer than a length in the horizontal direction of the interface layer.
 4. The photovoltaic device of claim 3, wherein the thickness of the n-doped GaAs layer from about 300 nm to about 3500 nm.
 5. The photovoltaic device of claim 3, wherein the n-doped layer has a doping level of 5×10¹⁶ to 5×10¹⁷ cm⁻³.
 6. The photovoltaic device of claim 3, wherein the n-doped AlGaAs intermediate layer comprises a graded aluminum composition. 